Cracked blend of propylene copolymer and E/VA

ABSTRACT

A new composition for the heat-sealable layer in a retort-sterilizable pouch is disclosed. The new composition is the cracked product of the blend of a poly(propylene-ethylene) copolymer and an ethylene-vinyl acetate copolymer. This composition has improved flow properties and may be extrusion-coated onto a metal film substrate at high speeds.

This is a division, of application Ser. No. 237,830, filed Feb. 25, 1981, now U.S. Pat. No. 4,359,495.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention is directed to a new composition useful as the heat-sealable layer in a retort-sterilizable pouch, and to a process for forming such a retort-sterilizable pouch.

1. Description of the Prior Art

The retortable pouch is a sterilizable, flexible, long shelf-life food package intended to compete with the conventional tin can. The pouch for foodstuffs is typically a laminate consisting of three plies, namely 0.5 mil polyester on the outside, 0.35 mil aluminum foil in the middle and 3.0 mil polypropylene copolymer or modified high density polyethylene film on the inside. Such laminated retort-sterilizable pouchs have been available for many years. See, e.g., U.S. Pat. No. 4,190,477 and U.K. Patent Application GB 2,027,391A.

One means to reduce costs and improve the product would be to extrusion coat the heat-sealable, polypropylene-based composition directly onto the aluminum rather than purchase film and carry out a laminating process. However, in order to achieve proper economics, it would be necessary to be able to deposit a 3 mil film at a coating speed of over about 400 feet per minute. In contrast, before now it has only been possible to achieve speeds of about 120 ft/min using conventional polymers or blends before uncontrolled surging (draw resonance) occurs. What is needed is a polymer composition that can be extruded at high speeds and that will result in a retort-sterilizable pouch having acceptable property values.

SUMMARY OF THE INVENTION

The present invention broadly encompasses a novel composition having improved flow properties, making it especially useful in retort-sterilizable pouches. The composition comprises the cracked product of the blend of a polypropylene copolymer and an ethylene-vinyl acetate copolymer wherein:

(a) the melt flow of said cracked product is between about 15 and about 50 grams per 10 minutes, (ASTM D1328 condition L);

(b) said polypropylene copolymer is a propylene-ethylene copolymer comprising between about 1 and about 10 percent by weight ethylene and has a melt flow of between about 0.5 and about 15 grams per 10 minutes, (ASTM D1328 condition L); and

(c) said ethylene-vinyl acetate copolymer has a vinyl acetate content of between about 15 and about 30 percent by weight, and has a melt flow of between about 1 and about 30 grams per 10 minutes, condition E.

Also contemplated herein are the process for extrusion of a polymer film on a substrate employing such a polymer composition and a retort-sterilizable laminated structure containing such a polymer composition as the heat-sealable polymer layer.

Compositions according to the present invention have been coated on substrates at speeds of greater than 400 feet per minute without evidence of any surging or draw resonance. Further, the property balance of polymer-metal laminates or retortable pouches containing such polymer compositions has been excellent. The use of compositions according to the present invention results in laminates having more than acceptable peel strength (adhesion), heat seal strength and impact resistance.

DETAILED DESCRIPTION OF THE INVENTION

There are two basic polymer components in the compositions of the present invention: a propylene-ethylene copolymer and an ethylene-vinyl acetate copolymer.

The propylene-ethylene copolymer (which may be random, block, or any combination thereof) preferably contains between about 1.0 and about 10 percent by weight ethylene, preferably between about 2.0 and about 6.0 percent by weight ethylene. Typical melt flow values are between about 0.5 and about 15 grams per 10 minutes, ASTM D1328 condition L, preferably between about 1 and about 10 grams per 10 minutes. These polypropylene copolymers are preferred over high density polyethylene since they can be retorted or sterilized at 120° C. versus 110° C. for high density polyethylene.

Preferred commercial polymers include Shell 6675 and 7522 copolymers and DN 6009, a developmental Shell grade.

The ethylene-vinyl acetate copolymers which are to be used in the compositions of the invention correspond to the general formula ##STR1## The actual occurrence of the acetate substituents along the hydrocarbon chain is of a random character and thus the letter m denotes the average number of ethylene units per vinyl acetate unit in the molecule rather than the presence of regularly recurrent units having the composition given within the above brackets. The percent by weight vinyl acetate in the copolymer ranges from about 15% to 30%, preferably from 18% to 28%. The most useful melt indicies range from about 2 to about 12 grams per 10 minutes. An excellent copolymer is DuPont's Elvax 360 which has a melt flow of 6.0, condition E, and contains about 25%w vinyl acetate.

The ethylene-vinyl acetate copolymer (EVA) is essential in order to give impact strength to the compositions. Accordingly, the compositions preferably contain between about 5 and about 20 percent by weight EVA, more preferably between about 6 and about 15 percent by weight EVA, the remainder consisting of the propylene-ethylene copolymer component.

The above polymer blends are then cracked to a melt flow of between about 15 and about 65 grams per 10 minutes, condition L. Preferred melt flow values are between about 15 and about 50 grams per 10 minutes, more preferably between about 15 and about 35 grams per 10 minutes.

Cracking of the polymer blend refers to subjecting the blend to thermal and/or chemical processes to crack the heavier components therein narrowing the molecular weight distribution and increasing the melt flow indicies. Among the various cracking processes which may be useful herein include high temperature thermal cracking, peroxide cracking, and radiation cracking. Thermal cracking involves subjecting the blend to temperatures above about 315° C. at elevated pressures for a sufficient time to increase the melt flow to the desired range. Radiation cracking includes both election beam and cobalt 60 methods. Standard techniques for the peroxide cracking of polymers in an extruder are well known and include the processes disclosed in U.S. Pat. No. 3,144,436 and U.S. Pat. No. 3,887,534. Preferred peroxides are aliphatic peroxides. The amount of peroxide and the cracking temperature depend upon the melt flows of the starting polymers and the desired melt flow of the final composition. Illustrative Embodiment I discloses the effect of varying peroxide content on melt flow. Typical amounts of peroxide are between about 300 parts by weight per million parts by weight total polymer (ppmw) and about 1500 ppmw. Typical cracking temperatures are between about 175° C. and about 300° C.

The cracked product is especially useful as the heat-sealable layer in a retort-sterilizable pouch. The overall construction of such pouches is disclosed in U.S. Pat. No. 4,190,477 and U.K. Patent Application No. 2,027,391A. One basic difference between the process according to this invention and the process disclosed in the above two cited patents, is that in the present invention the heat-sealable layer is formed by direct extrusion onto the aluminum foil or sheet, whereas in the two patents the heat-sealable layer is first formed into a ply which is then laminated onto the aluminum sheet.

The invention is further illustrated by reference to the following Illustrative Embodiments, which are given for the purpose of illustration only and are not meant to limit the invention to the particular reactants and conditions employed therein.

Illustrative Embodiment I

Illustrative Embodiment I discloses the effect that varying the amount of peroxide has on the melt flow of the resulting cracked product. In each case the polymer composition comprised a polypropylene copolymer and varying amounts of a vinyl acetate copolymer. The polypropylene copolymer was Rexene 32S5 containing 1% ethylene and having a melt flow (condition L) of 5. The ethylene-vinyl acetate copolymer was Elvax 360 having a nominal vinyl acetate content of 25% by weight and a melt flow (condition E) of 6.2.

The peroxide was added to the polymer blend in two different manners. In some cases the cracking was carried out using a peroxidepolyethylene masterbatch containing 4% active peroxide. In other cases the cracking was carried out using 100% liquid peroxide. In all cases the peroxide employed was an aliphatic peroxide.

The cracked product was obtained by extruding the polymers and the peroxide in a 21/2 inch MPM extruder using a melt temperature of 205° to 232° C. The results are presented below in Table 1.

                  TABLE 1                                                          ______________________________________                                         CRACKING OF POLYPROPYLENE                                                      CONTAINING ETHYLENE/VINYL                                                      ACETATE COPOLYMER WITH PEROXIDE                                                Percent     Peroxide Concentration, ppm                                                                       Melt Flow                                       Num-  by weight 4% Peroxide in                                                                             100% Liquid                                                                             Cond. L                                   ber   Elvax 360 Polyethylene                                                                               Peroxide g/10 min.                                 ______________________________________                                         1     5         0           --       6.2                                       2     5         700         --       27.0                                      3     5         850         --       28.5                                      4     5         1000        --       36.6                                      5     5         1000        --       38.1                                      6     10        0           --       6.0                                       7     10        1000        --       31.8                                      8     15        0           --       6.0                                       9     15        1000        --       30.0                                      16    10        --           0       6.2                                       17    10        --          500      24.2                                      18    10        --          800      31.7                                      ______________________________________                                    

Illustrative Embodiment II

In Illustrative Embodiment II, various compositions were prepared based on Shell DN 6005 (a polypropylene-ethylene copolymer), which contains about 1.9% by weight ethylene and has a melt flow, condition L of about 8. The other component in the blends was either Shell 0300 Polybutylene or Elvax 360 ethylene-vinyl acetate copolymer. The product compositions were made by extruding mixtures of copolymer powder with polybutylene or EVA pellets on a 21/2 inch Prodex extruder. The homogeneous blends were then coated with 100% liquid peroxide and re-extruded on the Prodex extruder to produce the cracked products. The products submitted for evaluation were as follows:

    ______________________________________                                                                              Melt                                      Number  Blend Component  Peroxide ppmw                                                                              Flow                                      ______________________________________                                         WRS 5-295                                                                              10% w. Polybutylene 0300                                                                        None         9                                        WRS 5-296                                                                              10% w. Polybutylene 0300                                                                        450         49                                        WRS 5-297                                                                              10% w. Elvax 360 900         62                                        ______________________________________                                    

The results (Table 2) obtained on the cracked products were highly encouraging. A speed run was made first on paper substrate at maximum screw rpm (150) to determine how fast the substrate can be run before surging (draw resonance) occurs. Since three mil films are required for testing, the films obtained during the speed test are usually too thin. After the speed test, aluminum foil was introduced to the system and coated at a screw speed of 90 rpm and a substrate speed of 100 ft/min to obtain a three mil coating.

For prior art compositions, coating speeds of only about 125 ft/min are achievable. The data on Table 2 show that an amazing substrate speed of 400 ft/min was achievable with compositions according to the present invention.

                                      TABLE 2                                      __________________________________________________________________________     EXTRUSION COATING OF ALUMINUM WITH POLYPROPYLENE                               FOR EVALUATION IN RETORTABLE POUCHES                                                           Melt Flow                                                            Polypropylene                                                                            Condition L  Substrate Speed Coating                           Number                                                                               Type      dg/min Screw rpm                                                                            ft-min  Melt Temp. °F.                                                                  Uniformity                        __________________________________________________________________________     WRS5-295                                                                             DN 6005 (1.9% Et)                                                                        9      150   250     520     surging                           WRS5-295                                                                             plus 10% Poly-   150   200     520     satisfactory                      WRS5-295                                                                             butylene 0300    90    100     520     excellent                         WRS5-296                                                                             DN 6005 (1.9% Et)                                                                        49     150   400     500     excellent                         WRS5-296                                                                             plus 10% Poly-   90    100     500     excellent                               butylene 0300                                                            WRS5-297                                                                             DN 6005 (1.9% Et)                                                                        62     150   400     470     excellent                         WRS5-297                                                                             plus 10% Ethylene                                                                               90    100     470     excellent                         WRS5-297                                                                             Vinyl Acetate    150   400     500     excellent                         WRS5-297                                                                             Copolymer        90    100     500     excellent                         WRS6-75                                                                              Rexene 13S-5.sup.1                                                                       5      150   120     520     excellent                         WRS6-76                                                                              Rexene 13S-5.sup.1                                                                       5      150   200     520     poor                              WRS-74                                                                               Rexene 23S-2(6313).sup.2                                                                 75     150   300     470     excellent                         __________________________________________________________________________      .sup.1 Random copolymer w. polypropylene postblock: 2.1% ethylene.             .sup.2 Random copolymer w. polypropylene postblock: 2.5% ethylene.       

Table 3 presents the evaluation of retortable pouches made from the compositions of Table 2. In the table, ND means not determined. Peel Strength, Heat Seal Strength and Drop Test are all standard tests in the industry. In the Drop Test, 10 pouches are dropped in each cycle. The product specification is that after 6 cycles, only 40% or less should fall.

From Table 3, it is clear that the low flow, uncracked polybutylene product, high flow, cracked polybutylene product and high flow, cracked EVA product all passed the peel strength and heat seal strength tests. However, the high flow, cracked polybutylene product clearly failed the drop test, while the other two products came very close. Since the low flow, uncracked polybutylene product cannot be coated at high speeds, it is clear that the cracked, high flow EVA product according to the present invention is superior to any of the other products. It is important to also point out that unmodified polypropylene polymers clearly failed the drop tests.

                  TABLE 3                                                          ______________________________________                                         EVALUATION OF RETORTABLE POUCHES MADE                                          FROM SHELL POLYPROPYLENE                                                                    Heat Seal   Drop Test                                             Peel         Strength lbs                                                                               % Failed                                              Strength     Before  After   Cycle Number                                      Number  lbs/in   Retort  Retort                                                                               1    2    5    6                                ______________________________________                                         WRS5-295                                                                               4.6      21      6.0    0    0   0     80                              WRS5-296                                                                               5.0      21      12-13  0   80   ND   100                              WRS5-297                                                                               3.0      17      12-13  0    0   0     60                              WRS6-75 3.0      ND      --    100  ND   ND   ND                               WRS6-74 3.4      17      --     40  ND   ND   100                              Product 2.5      12      --     0   --   --    40                              Minimum                                                                        ______________________________________                                    

Illustrative Embodiment III

Illustrative Embodiment III was conducted in a similar manner to Illustrative Embodiment II except for three basic modifications. These modifications were:

(a) raising the ethylene content in the copolymer from 1.9 to 2.4%,

(b) circulating air over the pellets in the Whitlock dryer to remove volatile cracking components, and

(c) raising the concentration of modifier from 10% to 12.5% in the case of EVA and from 10% to 20% in the case of the polybutylene.

The results of the coating trials (Table 4) were as follows: All the products passed the heat seal minimum. The 75 MF, EVA-containing product had exceptional adhesion; the others passed.

The extruder had been refitted and could be run at a maximum rpm of 250 rather than 150. A three mil coating could be obtained at an rpm of 250 and a substrate speed of 250 ft/min rather than the previous 90 rpm and 100 ft/min substrate speed.

As usual a speed-run on paper was made first to determine how fast the substrate speed could be run without obtaining surging (draw resonance). Aluminum foil was then introduced and conditions were set to give a 3 mil film. In this case an rpm of 250 and a substrate speed of 250 ft/min gave the desired thickness. The 75 melt flow EVA-modified product ran at a phenomenal rate of 600 ft/min without surging. The 50 MF, EVA product was only taken to 500 ft but probably could have been taken to 600 ft/min also. All of the polybutylene-modified products gave problems in that the overcoat (polymer beyond the substrate) stuck to the chill roll causing takeoff problems.

Evaluation of the pouches (Table 5) showed the following: Heat seal strength after retorting dropped below minimum specification. The 50 MF EVA modified product performed the best, giving a strength of 15 lbs. Competitive products pass this test but none of them can be coated at speeds above 300 ft/min.

Taste was much improved over previous samples and was close to being satisfactory. Taste is presumably due to peroxide fragments or by-products of cracking. These date indicate that distasteful by-products can be removed.

None of the products passed the minimum drop test specification. The 50 MF, EVA-modified product however came way close to passing with zero failures after 4 drops and only 6 failures after 6 drops vs. specification of a maximum of 4 failures out of 10 pouches after 6 drops.

                                      TABLE 4                                      __________________________________________________________________________     EXTRUSION COATING OF ALUMINUM WITH MODIFIED RANDOM COPOLYMER.sup.1                                        Sub-       Thickness                                Modifier % w           Screw                                                                              strate     Lbs           Strength Properties        Number                                                                              EVA      Melt                                                                               Melt Speed                                                                              Speed      Per     Coating                                                                              Adhesion                                                                            Heat Seal             WRS6 360 PBO300                                                                              Flow                                                                               Temp.                                                                               ft/Min                                                                             ft/min                                                                              Substrate                                                                            Ream                                                                               Mils                                                                               Conformity                                                                           Lbs  Lbs                   __________________________________________________________________________     91   12.5                                                                               --   75  500° F.                                                                       75  90  Paper --  --  --    --   --                    91   12.5                                                                               --   75  500° F.                                                                      240 250  Paper 35  2.5 exc.  --   --                    91   12.5                                                                               --   75  500° F.                                                                      250 250  Paper 39  3.0 exc.  --   --                    91   12.5                                                                               --   75  500° C.                                                                      250 600  Paper --  --  exc.  --   --                    91   12.5                                                                               --   75  500° F.                                                                      250 250  Aluminum                                                                             39  3.0 exc.  6.8,                                                                                25.5                  90   12.5                                                                               --   50  500° F.                                                                      250  500.sup.2                                                                          Paper --  --  exc.  --   --                    90   12.5                                                                               --   50  500° F.                                                                      250 250  Aluminum                                                                             39  3.0 exc.  3.5,                                                                                24, 25                89   --  20   50  500° F.                                                                      250 250  Paper --  --  (.sup.3)                                                                             --   --                    89   --  20   50  500° F.                                                                      250 250  Aluminum                                                                             --  --  exc.  3.5,                                                                                21-24                 88   --  20   50  500° F.                                                                      250 250  Paper --  --  exc.  --   --                    88   --  20    9  500° F.                                                                      250 300  Paper --  --  prob. ok                                                                             --   --                    88   --  20    9  500° F.                                                                      250 500  Paper --  --  surging.sup.4                                                                        --   --                    88   --  20    9  500° F.                                                                      250 250  Aluminum                                                                             --  --  exc.  4.5,                                                                                22.5, 23              Min                                                                            Spec                                                3.5.sup.5                                                                           22.sup.5              __________________________________________________________________________      .sup.1 E6005 type with 2.4% random                                             .sup.2 Appeared capable of 600 ft/min                                          .sup.3 Overcoated section stuck to chill roll giving appearance of             .sup.4 Operator estimated maximum speed without surging to be about 300        ft/min                                                                         .sup.5 Former minimums were 2.5 lbs for adhesion and 12 for heat seal    

                                      TABLE 5                                      __________________________________________________________________________     ALUMINUM COATED WITH MODIFIED RANDOM COPOLYMER -                               EVALUATION ON RETORTABLE POUCHES                                                                  Maximum                                                                              Heat Seal                                                                              Slide Drop Test.sup.1                                            Extrusion                                                                            Strength, lbs.                                                                         Number of Failures After                      Number                                                                              EVA Polybuty-                                                                            Melt                                                                               Speed Before                                                                             After                                                                              Number of Drops                                                                              Taste                           WRS6 360 lene 0300                                                                            Flow                                                                               ft/min                                                                               Retort                                                                             Retort                                                                             1  2 3 4 5 6  Test                            __________________________________________________________________________     91   12.5                                                                               --    75  600   25  12  0  1 1 4 8 10 very slight                                                                    close to o.k.                   90   12.5                                                                               --    50  >500  25  15  0  0 0 0 2  6 very slight                                                                    close to o.k.                   89   --  20    50  250   23  11  0  2 3 6 8 10 o.k.                            88   --  20     9  300   22  12  0  0 0 2 5  9 o.k.                            Speci-                                                                         fication       --  300   22  20  0- --                                                                               --                                                                               --                                                                               --                                                                                4 o.k.                                               min   min min 0.5.sup.2  max                                __________________________________________________________________________      .sup.1 Ten waterfilled pouches are dropped.                                    .sup.2 Zero out of 10 is preferred. If one breaks, a second ten are            tested. None of the second ten may fail.                                 

Illustrative Embodiment IV

From Illustrative Embodiment III it can be seen that seal strength and drop test are improved without sacrificing coating speed when the melt flow is dropped from 75 to 50. This suggests that a 25 melt flow material should give better seal strength and drop resistance and might still give high coating speeds. Accordingly, in Illustrative Embodiment IV the amount of peroxide was decreased from the amount used to WRS6-90 from Illustrative Embodiment III, resulting in a product (WRS6-93) having a melt flow of 25.

    ______________________________________                                         Polymer Number         WRS6-93                                                 % w EVA                12.5                                                    Melt Flow              25                                                      Peel Strength lb/in    5                                                       Heat Seal                                                                      Before retort lb       25                                                      After retort lb        18                                                      Slide drop test                                                                Failures after 6 drops 2                                                       ______________________________________                                    

These data show that properties were indeed improved without sacrificing extrusion speed by lowering the melt flow to 25.

Illustrative Embodiment V

According to FDA regulations (Federal Register Vol 45 No. 10 Tues. January 15, 1980, pages 2842-2844) the EVA content of retortable pouches cannot exceed 10%w. A product was therefore manufactured to meet these specifications as follows:

    ______________________________________                                         Polymer Number        WRS6-101                                                 Propylene ethylene                                                             copolymer with 2.4%                                                            ethylene              90.1%                                                    EVA 360               9.9% w                                                   Melt Flow of product  27                                                       ______________________________________                                    

The above product (WRS6-101) was run on commercial equipment and the following results were obtained:

    ______________________________________                                         Extrusion speed        satisfactory                                            Peel Strength lbs/in   5                                                       Heat Seal Strength lbs.                                                        Before retort          28                                                      After retort           27                                                      Slide drop test                                                                Failures after 6 drops 2                                                       Burst strength lbs.    75 (min 55)                                             Retortability at 250° F.                                                                       pass                                                    Retortability at 275° F.                                                                       pass                                                    ______________________________________                                    

This illustrates that a fully satisfactory product meeting FDA regulations as well as the customer specifications can be produced.

Illustrative Embodiment VI

A composition was prepared containing 90.1%w of a propylene-ethylene copolymer containing 4.4%w of ethylene and 9.9%w of EVA 360. This product was cracked to give a product with a melt flow of 30. This product when extrusion coated on aluminum foil gave the following results:

    ______________________________________                                         Product Number         WRS6-102                                                Peel Strength lbs/in   6                                                       Heat Seal Strength, lbs.                                                       Before retort          25                                                      After retort           20                                                      Retortability at 250° F.                                                                       pass                                                    Burst strength lbs.    70 (min 55)                                             ______________________________________                                     

What is claimed is:
 1. A composition having improved flow properties comprising the cracked product of a blend of a polypropylene copolymer and an ethylene-vinyl acetate copolymer wherein:(a) the melt flow of said cracked product is between about 15 and about 65 grams per 10 minutes, condition L; (b) said polypropylene copolymer is a propylene-ethylene copolymer comprising between about 1 and about 10 percent by weight ethylene and has a melt of between about 0.5 and about 15 grams per 10 minutes, condition L; and (c) said ethylene-vinyl acetate copolymer has a vinyl acetate content of between about 15 and about 30 percent by weight, and has a melt flow of between about 1 and about 30 grams per 10 minutes, condition E.
 2. The composition according to claim 1 wherein the melt flow of said cracked product is between about 15 and about 50 grams per 10 minutes.
 3. The composition according to claim 2 wherein said polypropylene copolymer is a random copolymer comprising between about 1 and about 10 percent by weight ethylene.
 4. The composition according to claim 1 wherein said cracked product is prepared by peroxide cracking.
 5. The composition according to claim 4 wherein said peroxide is an aliphatic peroxide.
 6. The composition according to claim 1 wherein said blend comprises between about 5 and about 25 percent by weight ethylene-vinyl acetate copolymer and between about 95 and about 75 percent by weight polypropylene copolymer. 